Method for making a novel steering wheel and the steering wheel produced thereby

Abstract

A novel method for making a steering wheel is provided. The steering wheel so produced is also provided. The steering wheel preferably comprises a hooped channel (felly) which is dimpled and pierced. A central hub assembly is also provided, the hub having also been pierced and the holes therein countersunk. The hub and channel are interconnected through the use of a plurality of spokes, preferably aesthetically arranged to generally correspond to the arrangement of spokes of a vehicle wheel with which the steering wheel may be used. Once appropriately interconnected, a grip is applied to the outer portion of the channel, and the steering wheel is then ready for use.

I claim: 
     
       1. A method for making a steering wheel mountable to a steering shaft, the method comprising the steps of: providing a hooped channel;   providing a central hub suitably configured for placement in the center of said hooped channel, said hub having means for connecting said hub to said steering shaft and means for receiving a horn button therein;   forming a plurality of holes in said hooped channel;   forming a corresponding plurality of holes in said hub;   providing a plurality of spokes for interconnecting said hooped channel and said hub, said spokes having a first and second end, said first end terminating in a head and said second end including a threaded portion, said head of said first end engageable with said holes in said hub and second threaded end engageable with said holes in said hooped channel; interconnecting said hub and said hooped channel with said spokes; providing a grip suitably configured to be disposed on the hooped channel; attaching said hub to the steering shaft through use of said attaching means; and affixing a horn button to said hub.   
     
     
       2. The method according to claim 1, wherein said step of forming a plurality of holes in said hooped channel comprises the steps of: forming a plurality of dimples on said hooped channel; and   piercing said hooped channel at said dimples.   
     
     
       3. The method for making a steering wheel according to claim 2 wherein said step of interconnecting comprises the steps of: inserting said spokes through said holes in said hub such that said first head ends of said spokes mates with said hub aperture;   inserting said second threaded ends of said spokes into said said holes in said hooped channel;   providing a plurality of nipples having a thread receiving portion therein;   inserting said nipples into said said holes in said hooped channel such that said second threaded ends of said spokes engage said thread receiving portion of said nipples; and   uniformly tightening said nipples to securely interconnect said hub and said hooped channel with said spokes.   
     
     
       4. The method for making a steering wheel according to claim 3 wherein said step of providing a hooped channel comprises providing a channel felly having first and second leg members. 
     
     
       5. The method for making a steering wheel according to claim 4 wherein said first leg is longer than said second leg. 
     
     
       6. The method for making a steering wheel according to claim 5 wherein said step of providing a grip comprises providing a grip having a first edge and a second edge. 
     
     
       7. The method for making a steering wheel according to claim 6 wherein said step of attaching said grip further comprises securing said grip to said hooped channel such that said second edge substantially mates with said second leg and said first edge forms a generally cosmetic interface with said first leg. 
     
     
       8. The method for making a steering wheel according to claim 1 wherein said step of forming holes in said hooped channel comprises dimpling and piercing said hooped channel to provide a series of apertured protuberances on the inner side of said hooped channel. 
     
     
       9. The method of making a steering wheel according to claim 8 wherein said step of forming holes in said hub comprises: forming a first set of a substantially equidistantly spaced apertures in the side wall of a base of said hub, and   forming a second set of substantially equidistantly spaced apertures in said base side wall.   
     
     
       10. The method for making a steering wheel according to claim 9 wherein said step of forming a second set of apertures further comprises forming said apertures at an angle with respect to the center line of said aperture, said angle being on the order of about 2° to about 6°. 
     
     
       11. The method for making a steering wheel according to claim 10 wherein said step of forming holes in said hub further comprises the step of countersinking said first and second sets of apertures. 
     
     
       12. The method for making a steering wheel according to claim 11 wherein said step of interconnecting comprises: threading said spokes through said first and second sets of hub apertures such that said spoke first head ends seat in said hub apertures;   aligning said spoke second threaded ends with said dimpled and pierced apertures in said hooped channel; and   providing a plurality of nipples having a thread receiving portion, placing said nipples through said apertures in said hooped channel and attaching said nipple thread receiving portions to said threaded ends of said spokes.   
     
     
       13. A steering wheel mountable to a steering shaft comprising: a channel felly having a plurality of holes formed therein, said felly providing a grip interface;   a hub assembly suitably configured for attachment to the steering shaft of a vehicle and having a plurality of holes formed therein;   a plurality of spokes having first and second ends, said first ends of said spokes terminating in a head and said seconds ends of said spokes having at least a portion thereof which includes a threaded portion;   a plurality of nipples having a thread receiving portion therein;   wherein said first ends of said spokes are engageable with said holes in said hub assembly, said second ends of said spokes are engageable with said holes in said channel felly, and said nipple thread receiving portions are engageable with said spoke second ends such that said spokes interconnect said hub and said channel felly;   a grip disposed on said grip interface; and   a horn button assembly affixable to said hub assembly.   
     
     
       14. The steering wheel of claim 13 wherein said grip comprises: an accurate upper surface;   a front lip;   a back edge; and   a lower surface;   wherein said upper surface terminates in said front lip and said back edge, and said lower surface connects said front lip and said back edge.   
     
     
       15. The steering wheel of claim 14 wherein said grip further includes: a plurality of apertures positioned about the circumference of said grip; and   said steering wheel further includes a plurality of set screws, said set screws receivable within said grip aperture to secure said grip to said hooped channel.   
     
     
       16. The steering wheel of claim 13 wherein said holes in said hooped channel display an interconnecting protuberance. 
     
     
       17. The steering wheel of claim 16 wherein said holes in said hub assembly display an interconnecting circular depression. 
     
     
       18. The steering wheel of claim 17 wherein said holes in said hub assembly comprise first and second sets, said second set offset from a center line passing through the axis of said second set of holes. 
     
     
       19. The steering wheel of claim 18 wherein said offset is between about 2 and about 6° from said center line.